Rocker one-way clutch with cutout to locate a spring and stator incorporating the same

ABSTRACT

A rocker one-way clutch including an outer race including a pocket and a strut including a main body rotatable within the pocket and a locking member including a first neck portion extending from the main body and a cutout operatively arranged within the first neck portion to prevent displacement of a spring member. A rocker one-way clutch including an inner race, an outer race arranged radially outward of the inner race concentrically, the outer race including a pocket, a strut including a main body rotatable within the pocket and a locking member, the locking member including a first neck portion extending from the main body, a cutout operatively arranged within the first neck portion to prevent displacement of a spring member and a protrusion operatively arranged within the first neck portion opposite of the cutout to ensure proper assembly of the strut within said inner and outer races.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. § 119(e) of U.S.Provisional Patent Application No. 62/057,491, filed Sep. 30, 2014,which application is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The invention relates generally to a rocker one-way clutch, and, inparticular, a stator having a rocker one-way clutch having a cutout on astrut to maintain the position of a spring and a mechanism for ensuringthe strut is properly assembled within the stator.

BACKGROUND

U.S. Patent Application Publication No. 2013/0213027 (Bird et al.)discloses a one-way brake for a torque converter stator. The statordisclosed is formed with blades spaced mutually angularly about an axis.The stator disclosed further includes a hub located radially inward ofthe blades. The stator includes an outer race which includes pocketsspaced angularly about the axis. Each pocket includes a rocker,sometimes called a strut, and a spring, which continually urges arespective rocker to pivot in its pocket toward engagement with camsformed on an outer surface of the inner race, arranged radially inwardof the hub. The one-way rocker brake prevents counterclockwise rotationof the stator relative to the stator shaft and race.

U.S. Patent Application Publication No. 2014/0197002 (Lindemann et al.)discloses a symmetrical strut for a rocker one-way clutch that providesthe same functionality whether installed with a top or a bottom sideinto a pocket for a race for the clutch.

A common problem with rocker one-way clutches is that the springarranged between the housing and the strut can move out of place becausethe position of the spring is not maintained. Typical rocker one-wayclutch 50 is shown in FIG. 2. Strut 51 is rotatably mounted within apocket of housing 52 and spring 54 is wedged in groove 55. Spring 54 issimultaneously contacting strut 51. Spring 54 can slip along the surfaceof strut 51 along directions d1 and d2 shown in FIG. 3. If spring 54 ofsuch a rocker one-way clutch slips and/or becomes jammed, then thetorque converter fails to perform the multiplication function properly.Additionally, if spring 54 breaks, total replacement is necessary.

Another problem with rocker one-way clutches having an asymmetricalstrut is that the strut can be unintentionally incorrectly assembled.Typical rocker one-way clutch 50 shown in FIG. 2 includes improperlyinstalled strut 56 which has caused spring 58 to become dislodged fromgroove 59 of housing 52. In this improper arrangement, the contact anglebetween strut 56 and ramp 60 of inner race 61 is incorrect.Additionally, due to this improper arrangement, spring 58 can slipand/or become dislodged or jammed between strut 56 and housing 52.During operation of the rocker one-way clutch in the free-wheel mode,strut 56 can crush spring 58 as strut 56 is urged clockwise. A damagedspring can cause failure of one-way clutch 50 because a crushed springcan cause the inner and outer races to be non-rotatably locked.

FIG. 4a shows a perspective view of strut 51 which broadly includes mainbody 62, first neck portion 63 a and second neck portion 63 b. Main body62 is arranged to engage with and be restrained by a pocket of housing52 shown in FIGS. 2 and 3. First and second neck portions 63 a and 63 bare arranged to lock the inner and outer races of the one-way clutch.Strut 51 has top surface 64. When strut is properly installed in aone-way clutch, top surface 64 is facing upward and second neck portion63 b is facing radially outward. FIG. 4b shows a perspective view ofstrut 51 with bottom surface 65 facing upward. When bottom surface 65 isfacing upward, strut 51 can be improperly assembled in a statorassembly. First neck portion 63 a is substantially planar on allsurfaces even on the surface arranged to contact a spring.

Thus, there has been a long-felt need for a strut having a cutout tomaintain the position of a spring and a mechanism for ensuring the strutis properly assembled within the stator.

SUMMARY

According to aspects illustrated herein, there is provided a rockerone-way clutch including an outer race including a pocket and a strutincluding a main body rotatable within the pocket and a locking member,the locking member including a first neck portion extending from themain body and a cutout operatively arranged within the first neckportion to prevent displacement of a spring member.

According to aspects illustrated herein, there is provided a rockerone-way clutch including an inner race, an outer race arranged radiallyoutward of the inner race concentrically, the outer race including apocket, a strut including a main body rotatable within the pocket and alocking member, the locking member including a first neck portionextending from the main body, a cutout operatively arranged within thefirst neck portion to prevent displacement of a spring member and aprotrusion operatively arranged within the first neck portion oppositeof the cutout to ensure proper assembly of the strut within said innerand outer races.

According to aspects illustrated herein, there is provided a stator fora torque converter including a plurality of blades and a one-way clutchincluding an outer race located radially inward of the plurality ofblades and including a pocket and a strut including a main body arrangedin the pocket and a locking member including a first neck portiondirectly connected to the main body and extending from the main body ina first direction, the first neck portion having a first surface and acutout arranged in the first surface extending in a second direction toprevent displacement of a spring member.

A primary object of the invention is to provide a strut having a cutoutto maintain the position of a spring.

Another object of the invention is to provide a mechanism for ensuringthe strut is properly assembled within the stator.

These and other objects, features and advantages of the presentinvention will become readily apparent upon a review of the followingdetailed description of the invention, in view of the drawings andappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The nature and mode of operation of the present invention will now bemore fully described in the following detailed description of theinvention taken with the accompanying figures, in which:

FIG. 1 is a perspective view of a cylindrical coordinate systemdemonstrating spatial terminology used in the present application;

FIG. 2 is a top view of a rocker one-way clutch with a typical strut ina stator for a torque converter;

FIG. 3 is a fragmentary view of the rocker one-way clutch shown in FIG.2 illustrating a detailed view of the strut shown encircled in FIG. 2;

FIG. 4a is a perspective view of a typical strut of a rocker one-wayclutch;

FIG. 4b is a perspective view of the typical strut shown in FIG. 4aexcept with the top surface facing downward;

FIG. 5a is a perspective view of a strut of the invention;

FIG. 5b is a perspective view of the strut of the invention shown inFIG. 5a except with the top surface facing downward;

FIG. 6 is a fragmentary top view of a rocker one-way clutchincorporating the strut of the invention shown in FIG. 5; and,

FIG. 7 is a fragmentary view of the rocker one-way clutch incorporatingthe strut of the invention shown in FIG. 6 except with the springremoved.

DETAILED DESCRIPTION

At the outset, it should be appreciated that like drawing numbers ondifferent drawing views identify identical, or functionally similar,structural elements of the invention. It is to be understood that theinvention as claimed is not limited to the disclosed aspects.

Furthermore, it is understood that this invention is not limited to theparticular methodology, materials and modifications described and assuch may, of course, vary. It is also understood that the terminologyused herein is for the purpose of describing particular aspects only,and is not intended to limit the scope of the present invention.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood to one of ordinary skill inthe art to which this invention pertains. It should be understood thatany methods, devices or materials similar or equivalent to thosedescribed herein can be used in the practice or testing of theinvention.

FIG. 1 is a perspective view of cylindrical coordinate system 10demonstrating spatial terminology used in the present application. Thepresent application is at least partially described within the contextof a cylindrical coordinate system. System 10 includes longitudinal axis11, used as the reference for the directional and spatial terms thatfollow. Axial direction AD is parallel to axis 11. Radial direction RDis orthogonal to axis 11. Circumferential direction CD is defined by anendpoint of radius R (orthogonal to axis 11) rotated about axis 11.

To clarify the spatial terminology, objects 12, 13, and 14 are used. Anaxial surface, such as surface 15 of object 12, is formed by a planeco-planar with axis 11. Axis 11 passes through planar surface 15;however any planar surface co-planar with axis 11 is an axial surface. Aradial surface, such as surface 16 of object 13, is formed by a planeorthogonal to axis 11 and co-planar with a radius, for example, radius17. Radius 17 passes through planar surface 16; however any planarsurface co-planar with radius 17 is a radial surface. Surface 18 ofobject 14 forms a circumferential, or cylindrical, surface. For example,circumference 19 is passes through surface 18. As a further example,axial movement is parallel to axis 11, radial movement is orthogonal toaxis 11, and circumferential movement is parallel to circumference 19.Rotational movement is with respect to axis 11. The adverbs “axially,”“radially,” and “circumferentially” refer to orientations parallel toaxis 11, radius 17, and circumference 19, respectively. For example, anaxially disposed surface or edge extends in direction AD, a radiallydisposed surface or edge extends in direction R, and a circumferentiallydisposed surface or edge extends in direction CD.

FIG. 5a shows strut 100 of the invention with top surface TS facingupward.

FIG. 5b shows strut 100 with bottom surface BS facing upward. Cutout 106is arranged to prevent spring S (shown in FIG. 6) from inadvertentlyslipping in either direction d3 or direction d4.

FIG. 6 is a fragmentary top view of stator assembly 90 incorporatingstrut 100 of the invention shown in FIGS. 5a and 5b . Top surface TS ofstrut 100 is facing upward in FIG. 6 and thus, strut 100 is properlyassembled.

The following should be appreciated in view of FIGS. 5a, 5b , and 6.Strut 100 of the invention is arranged within outer race OR and innerrace IR of stator assembly 90. In a preferred embodiment, statorassembly 90 includes six struts 100 arranged symmetricallycircumferentially. The side plate of stator assembly 90 is not shown inFIG. 6 so that strut 100 is visible. In a preferred embodiment,plurality of blades (shown in FIG. 2) are arranged radially outward ofouter race OR. Additionally, a stator shaft (not shown) is arrangedradially inward of inner race IR. Inner race IR is non-rotatablyconnected to the stator shaft. Outer race OR is rotatable with respectto inner race IR in direction d5 and non-rotatable in direction d6 dueto the interaction between locking member 102 of strut 100 and pluralityof ramps 111 of inner race IR. In a preferred embodiment, direction d5is clock-wise and direction d6 is counterclockwise. During operation andunder acceleration when torque is multiplied, fluid is directedclockwise and strut 100 prevents outer race OR from rotating withrespect to inner race IR.

Strut 100 broadly comprises main body 101 and locking member 102. Mainbody 101 sits loose in pocket 112 so that main body 101 is rotatable.Locking member 102 includes first neck portion 103 and second neckportion 104. First neck portion 103 extends from main body 101 indirection d4. In other words, first neck portion 103 extends outwardlyradially from main body 101. First neck portion 103 also connects mainbody 101 to second neck portion 104. First neck portion 103 includesprotrusion 105 and cutout 106 and both protrusion 105 and cutout 106extend between top surface TS to bottom surface BS of first neck portion103. In a preferred embodiment, protrusion 105 is opposite cutout 106.Cutout 106 is arranged on front surface 114 and includes surfaces 106 a,106 b, and 106 c. Protrusion 105 is arranged on, and protrudes from,rear surface 113. Second neck portion 104 includes protrusion 104 a.

As shown in FIG. 6, cutout 106 is arranged to receive spring S andprevent spring S from accidentally slipping toward main body 101 ortoward second neck portion 104. More specifically, cutout 106 isoperatively arranged to receive first end 108 of spring S. Second end109 of spring S is wedged in groove 110. Thus, it should be appreciatedthat cutout 106 is correspondingly shaped and sized to maintain theposition of spring S based on the size of spring S.

Spring S is preferably a compression spring; however, any suitablealternative is contemplated. For example, spring S could be any rubberelement or a pneumatic cylinder. In an example embodiment, strut 100 ismade of powder metal having a microhardness of approximately 55-62 HRCand an apparent hardness of approximately 30 HRC min. In another exampleembodiment, strut 100 could be made of FLC2-4808-110HT or FLC 4608-95HT,which are designations for different variations of ferrous powder metalsthat are heat treated. Strut 100 can also be made of steel, for example,SAE J403, which is a hard carbon steel classified by the Society ofAutomotive Engineers, with a hardness of approximately 55-62 HRC. Anysuitable alternative is contemplated. The abbreviation “HRC” is adesignation of hardness using the Rockwell C Scale, measured by pressinga specially shaped diamond cone against a clean prepared surface of thespecimen with a specific force. The machine making the indention alsomeasures the depth of the indention and provides a numerical value forthat depth. It should be appreciated that any material that is very hardand resistant to permanent shape change when a compressive force isapplied is contemplated. In an example embodiment, strut 100 must bemade from a hard material to resist deformation due to the constantvariation of compressible forces.

FIG. 7 shows strut 100 within stator assembly 90 without spring S.Projection 120 is positioned on the inside of outer race OR such thatprojection 120 protrudes into pocket 112. If strut 100 is placed withinpocket 112 upside down such that cutout 106 is facing away from groove110 (instead protrusion 105 is facing groove 110), in that case,projection 120 contacts protrusion 105. Due to the contact betweenprotrusion 105 and projection 120, strut 100 does not sit fully withinpocket 112. Instead, strut 100 is prevented from sitting within pocket112 because protrusion 105 is sitting atop projection 120. When strut100 is not fully within pocket 112, the side plate of stator assembly 90cannot be assembled because strut 100 is not flush with its surroundingpocket 112. It should be appreciated that projection 120 can take anysuitable shape. Additionally, projection 120 could be one of a number ofprojections arranged to contact protrusion 105.

In a preferred embodiment, projection 120 is cast with outer ring OR.However, projection 120 could be a separate component and coupled withouter ring OR. It should also be appreciated that projection 120 doesnot interfere with spring S when and strut 100 is properly assembled. Inthat case, projection 120 is behind or underneath spring S.

In a preferred embodiment, strut 100 is forged of the materialsdescribed above however, any suitable alternative material or process offorming strut 100 can be used. Additionally, strut 100 can be used withany one-way clutch application.

It will be appreciated that various of the above-disclosed and otherfeatures and functions, or alternatives thereof, may be desirablycombined into many other different systems or applications. Variouspresently unforeseen or unanticipated alternatives, modifications,variations, or improvements therein may be subsequently made by thoseskilled in the art which are also intended to be encompassed by thefollowing claims.

REFERENCE NUMBERS

-   50 typical one-way rocker clutch-   51 strut-   52 housing-   54 spring-   55 groove-   56 improperly installed strut-   58 dislodged spring-   59 groove-   60 ramp-   61 inner race-   62 main body-   63 a first neck portion-   63 b second neck portion-   64 top surface-   65 bottom surface-   d1 direction-   d2 direction-   18 pocket-   90 stator assembly-   100 strut-   101 main body-   102 locking member-   103 first neck portion-   104 second neck portion-   104 a protrusion-   105 protrusion-   106 cutout-   106 a first surface-   106 b second surface-   106 c third surface-   108 first end-   109 second end-   110 groove-   111 plurality of ramps-   112 pocket-   113 rear surface-   114 front surface-   d3 direction-   d4 direction-   d5 direction-   d6 direction-   S spring-   120 projection-   TS top surface-   BS bottom surface-   OR outer race-   IR inner race

What is claimed is:
 1. A rocker one-way clutch, comprising: an innerrace; an outer race arranged radially outward of said inner raceconcentrically, said outer race including a pocket; a strut including atop planar surface and a bottom planar surface, the strut comprising: amain body rotatable within said pocket about an axis of rotation of thestrut; and a locking member, said locking member including: a neckportion extending from said main body; said neck portion beingasymmetrical about a plane extending from the axis of rotationincluding: a front surface arranged orthogonal to the top planarsurface; and, a rear surface arranged parallel to the front surface; acutout disposed within said front surface to prevent displacement of aspring member, said cutout facing said outer race and extending betweensaid top and bottom planar surfaces, said cutout comprising: a firstplanar surface arranged parallel to the front surface; a second planarsurface arranged nonparallel to the front surface; and a third planarsurface arranged nonparallel to the front surface; a first protrusionarranged on said front surface and extending toward said outer race;and, a second protrusion arranged on said rear surface and extendingtoward the inner race, said second protrusion operatively arranged tocontact a component of said outer race when said strut is assembled witha stator incorrectly.
 2. The rocker one-way clutch recited in claim 1,wherein said outer race includes a groove and said spring memberincludes a first end and a second end, and wherein said first end ofsaid spring member is arranged in said groove and said second end ofsaid spring member is arranged within said cutout, and said springmember is arranged to push said locking member radially inward from saidouter race into locking engagement with said inner race in a firstdirection.
 3. The rocker one-way clutch recited in claim 1, wherein:said outer race is rotatable with respect to said inner race in a firstdirection; and, in a second direction, said spring member is operativelyarranged to cause a first end of said locking member to contact saidinner race such that said outer race is non-rotatable with respect tosaid inner race.
 4. The rocker one-way clutch recited in claim 1,wherein said outer race includes a groove to hold said spring member,and said cutout and said second protrusion are substantially alignedwith said groove.
 5. A stator for a torque converter, comprising: aplurality of blades; and, a one-way clutch comprising: an outer racelocated radially inward of said plurality of blades and including: apocket; and, a projection; and a strut including a planar top surfaceand a planar bottom surface, the strut comprising: a main body arrangedin said pocket and rotatable about an axis of rotation; a locking memberincluding: a front surface facing said outer race; and a cutout arrangedin said front surface and extending from said top planar surface to saidbottom planar surface, said cutout having at least a first planarsurface and a second planar surface, facing said outer race; and, aprotrusion operatively arranged to contact said projection when saidstrut is assembled with said stator incorrectly.
 6. The stator for thetorque converter recited in claim 5, wherein said locking member extendsfrom said main body in a first direction and said cutout extends in asecond direction, said first direction is substantially perpendicular tosaid second direction.
 7. The stator for the torque converter recited inclaim 6, wherein a spring member is prevented from becoming displaced insaid first direction.
 8. The stator for the torque converter recited inclaim 5, wherein said outer race includes six pockets for six struts. 9.The stator for the torque converter recited in claim 5, wherein saidprojection is positioned within said stator in a position which is atleast partially aligned with said protrusion.
 10. The stator for thetorque converter recited in claim 9, wherein if said strut is assembledwithin said stator upside down, said projection will contact saidprotrusion and prevent said strut from sitting flush within said stator.